Abstract: The present invention provides a lithium metal battery having a lithium metal electrode including a cathode, an anode, a separator positioned between the cathode and the anode, an electrolyte, and a lithium metal negative electrode. The lithium metal negative electrode includes a lithium reactive metal layer, the lithium reactive metal layer being formed on a support conductive layer. A dendrite-suppressing coating is formed over the lithium reactive metal layer; the dendrite-suppressing coating is a displacement-reacted metal including silver reacted from decomposition of a silver salt and having an interface reaction product formed from a reaction between the silver salt and the lithium reactive metal layer. The interface reaction product is positioned between the displacement-reacted metal layer and the lithium reactive metal layer. The dendrite suppressing coating permits lithium metal ions to permeate the coating to react electrolytically in an overall battery reaction.

Abstract: A solventless method of making a dry electrode for an electrochemical cell is provided. A solventless electrode material mixture includes 85-99% electrode active material and from 0-10% conductive carbon additive. A polymer binder system is present from 1-15%. The polymer binder system includes one or more polymer binders. The electrode material mixture is mixed at a temperature greater than a softening point or a melting point of at least one polymer binder of the polymer binder system. The electrode material mixture is kneaded into an electrode material dough. The electrode material dough is formed into an electrode material sheet. At least a portion of the electrode material sheet is affixed to a metal current collector to form an electrode.